6.12 Green Brake System 2 – Process development

REFERENCE SPOKE
Spoke 6
OTHER SPOKES

Spoke 3

PROJECT LEADER
Carlo Panzeri
START DATE
Luglio 2024
END DATE
Dicembre 2025
PROPOSER
Brembo S.p.A
PARTNERS

Politecnico di Milano 
6.12 Green Brake System 2 – Process development

Development of an innovative brake system, able to reduce the PM10 emission according to new Euro7 norm. Target is a reduction of more than 65% of the emission respect to the traditional braking system.

The project aims to develop a new brake friction material on brake disc component adding a specific coating layer to the standard cast iron, based on innovative technology of additive manufacturing. Two technologies research lines has been approached: Laser Metal Deposition and Cold Gas Spray. The comparison between the 2 technologies will be explored through mainly experimental approaches guided by statistical techniques for experimental design, such as DoE.

RISULTATI ATTESI

Product development:

  • Development of coating layer that reduce the PM10 brake emission more than 65% respect to traditional brake system (currently in the market)
  • Characterization of metallic microstructure to guarantee the quality and durability in all final user conditions and highest sustainability (energy and materials)
  • Validation test campaign to validate all final users condition

Process development:

  • Application of Additive Manufacturing technology with metallic powder efficiency above 85% reached through process parameter DOE
  • Process optimization to define the larger parameter limits maintaining stable product quality
  • Process optimization to define the larger parameter limits maintaining stable machining quality and highest sustainability (energy and materials)
  • Develop dynamic parametric machining based on coating thickness through the design of a dedicated Industrial IoT architecture

Quality:

  • Research of a not destructive measurement system of the layer thickness (currently not available in the market)

Project n.: PE_00000004
MADE IN ITALY CIRCOLARE E SOSTENIBILE
C.F. 97931690156

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